Orthodontics
In our dental laboratory, we manufacture two types of orthodontic devices: children’s orthodontic appliances for bite correction and various types of aligners (including invisible braces). We produce whitening, sports, occlusal (for bruxism), and retention aligners.
We do not only manufacture orthodontic appliances based on an existing treatment plan, but we also develop and plan the treatment stages with our own resources. Our own planning and production allow us to guarantee a particularly high-quality treatment outcome.
As part of orthodontic appliance production, we create dental plates (brackets) and monoblocks. The main difference between a monoblock and a plate is that the monoblock is a single structure for both the upper and lower jaws, working in the bite. In contrast, a plate is used only for one jaw.
We accept an alginate impression or an intraoral scan. Depending on the type of impression, we create a model from plaster or with 3D printing. Based on the movements and shifts required by the orthodontic treatment plan, we bend a “clamping” construction of the necessary shape from metal wire. Then, we select the appropriate expansion screw for the structure.
To separate the future appliance from the model, we coat the model’s surface with Ivoclar Separation Fluid. After the separator dries, we attach all previously prepared metal constructions to the model using wax.
The appliance body is manufactured using cold polymerization technology. The powder of special orthodontic plastic Orthocryl or Ivoclar Triplex plastic is mixed with water in simpler cases, and the technician manually models the appliance surfaces from the resulting mass. The mass must cover some parts of the metal structures because it is what binds them into a unified appliance.
The surface modeled by the technician is covered with a monomer (hardener) and themed children’s pictures are applied to it. The entire structure is placed in the Ivoclar Ivomat IP3 polymerization chamber and undergoes the curing process. The finished model requires minimal manual processing and polishing by the technician. The orthodontic appliance is supplied with a set of activation keys for both the doctor and the patient.
For manufacturing various types of aligners, we accept a dental impression or an intraoral scan. Depending on the type of impression, we create a model from plaster or with 3D printing. Aligners are made from special plastic blanks, which vary in their set of properties. The technician selects the appropriate thickness, rigidity, and color based on the type of aligner ordered. We also work with blanks that are 3-4 mm thick, which allows us to manufacture durable sports aligners.
If certain anatomical features of the jaw or dental arch may interfere with putting on or removing the aligner, the technician adjusts the model’s shape using special orthodontic silicone, Erkoskin. If the aligner is a whitening one, the areas and cavities designated for applying the whitening gel are also shaped with silicone.
The shaping of the blank takes place in the FORESTADENT Track V machine. The blank is placed in a special holder, while the model is positioned in a tray filled with metal granules resembling small beads, located below. This tray is needed to immerse the base of the plaster model. Without the granules, the blank would wrap around the base walls of the plaster model, making it impossible to separate the aligner from the model. Due to their shape, the granules do not stick to the aligner and can be easily removed using a magnet.
FORESTADENT Track® V is a vacuum thermoforming device designed for the production of aligners and splints in orthodontic practice. Its versatility allows the creation of various types of orthodontic appliances for bite correction and treatment stabilization.
After placing all components into the machine, the technician selects the type and thickness of the blank on the machine’s screen. The machine then sets the required heating temperature for the blank before shaping. Once the set temperature is reached, the technician lowers the holder with the softened blank onto the model. Within seconds, the blank cools and hardens, taking on the exact shape of the model.
The finished aligner is trimmed to the required boundary for its intended use. The edges are refined with grinding and polishing discs. After post-processing with discs, the technician uses a special burner to slightly melt the edges, rounding them for a smooth finish.
